CFD Simulation and Structural Optimization Analysis of Micromixing Processes in T-Shaped Microreactors

Area of Science:

• Chemical Engineering
• Fluid Dynamics
• Reaction Engineering

Background:

• Microreactors enhance mixing and mass transfer for industrial applications.
• T-shaped microreactors (TMRs) are investigated for improved process intensification.
• Optimizing microreactor design is crucial for efficient chemical processing.

Purpose of the Study:

• To design and evaluate T-shaped microreactors with integrated baffle, orifice-plate, and venturi structures.
• To simulate fluid flow, mixing, and reaction processes using computational fluid dynamics (CFD).
• To determine the optimal structure for enhanced micromixing efficiency and minimal pressure drop.

Main Methods:

• Development of three-dimensional CFD models based on the Villermaux-Dushman reaction system.
• Simulation of fluid flow, turbulent kinetic energy, and turbulent dissipation rates.
• Application of the agglomeration model to determine micromixing times.

Main Results:

• Velocity, turbulent kinetic energy, and dissipation rate peaks occur at the confluence region.
• Baffle structures show highest micromixing but largest pressure drop; orifice-plate is intermediate.
• Venturi structures enhance micromixing, minimize pressure drop, and eliminate dead zones.

Conclusions:

• The venturi structure with a 45° contraction angle provides an optimal balance between energy consumption and micromixing efficiency.
• Microreactor structures significantly impact mixing performance and pressure drop.
• Optimized microreactor designs are essential for efficient industrial chemical processes, with micromixing times ranging from 0.025 to 0.234 ms.